model ar2 wiring harness

Model AR2

Wiring Harness

WIRING HARNESS ASSEMBLY

2

BILL OF MATERIALS

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5

(you will need 2 packs of 10 aviation plugs)

6

(Make sure you buy high quality non roller switch for J6 – note the rivet hinge pin)

7

You will need 1 limit switch tip

For J6, this part must be 3D printed.

The print file can be found on

The project page with all the other

3D print files.

SECTION 1

FEMALE 4 PIN JST CONNECTOR FOR

MOTOR END OF WIRING HARNESS

8

NOTE THAT THE GAP ON THE PIN

INSULATION WINGS IS TYPICALLY TOO

WIDE OR TOO OPEN.

BEND AND BREAK OFF FEMALE PIN

FROM STRIP.

THE GAP SHOULD NOW LOOK LIKE

THIS.

USE NEEDLE NOSE PLIERS TO CLOSE THE

GAP AS SHOWN

STRIP END LEAVING APPROX 3mm OF

WIRE EXPOSED ON ALL 4 WIRES.

PLACE END OF RIBBON WIRE IN SELF

ADJUSTING WIRE STRIPPERS AS SHOWN.

NOTE THE LIP OR STEP IN THE UPPER

JAW OF THE CRIMPING TOOL.

USE CUTTERS OR RAZOR KNIFE TO

SEPARATE WIRES.

CLOSE THE CRIMPER SLOWLY INTIL THE

RATCHET MECHANISM CLICKS 3 TIMES

BUT DO NOT FULLY CLAMP. IT SHOULD

LOOK LIKE THIS.

WITH CRIMPING TOOL UPSIDE DOWN

IN YOUR LEFT HAND PLACE THE FEMALE

PIN INTO THE JAW WITH YOUR RIGHT

HAND AS SHOWN. THE WINGS

SHOULD BE UP AGAINST THE STEP

SHOWN IN THE PREVIOUS STEP..

THIS PICTURE SHOWS WHERE THE WIRE

SHOULD BE SITTING INSIDE THE PIN.

NOTE THE JACKET IS JUST PAST THE

LARGE WINGS AND THE WIRE ITESELF IS

INSIDE THE SMALLER SET OF WINGS.

IT WILL TAKE PRACTICE TO GET A FEEL

FOR HOW TO INSERT THE WIRE INTO

THE CRIMPER TO GET THIS ALIGNMENT.

FLIP THE CRIMPER BACK RIGHT SIDE UP

AND HOLD WITH YOUR RIGHT HAND,

THEN STARTING WITH THE BLUE WIRE

AS SHOWN – INSERT THE WIRE INTO

THE CRIMPER AND PIN.

THIS PICTURE SHOWS HOW IT SHOULD

LOOK AFTER BEING CRIMPED.

NOTE THE JACKET IS FULLY CLAMPED

BY THE LARGE WINGS BUT THE JACKET

STOPS RIGHT AT THE SMALLER WINGS

AND THE SMALLER WINGS HAVE

CLAMPED ONLY THE METAL WIRE.

I SUGGEST PRACTICING THIS SEVERAL

TIMES TO GET THE HANG OF IT BEFORE

TRYING TO MAKE YOUR WIRING

HARNESS.

WITH THE WIRE AT THE CORRECT

DEPTH COMPETEY CLAMP THE CRIMPER.

THIS PICTURE ALSO SHOWS AN

INCORRECTLY CRIMPED

CONNECTOR.

NOTE THE WIRE WAS INSERTED

TOO FAR AND THE JACKET IS

CLAMPED BY BOTH THE LARGE

AND SMALL WINGS.

THIS IS NOT ACCEPTABLE – IF IT

LOOKS LIKE THIS YOU NEED TO RE-

DO IT..

THIS PICTURE SHOWS AN

INCORRECTLY CRIMPED

CONNECTOR.

NOTE THE JACKET IS NOT FULLY

INSIDE OR CLAMPED BY THE

WINGS.

THIS IS NOT ACCEPTABLE – IF IT

LOOKS LIKE THIS YOU NEED TO RE-

DO IT.

CUT A LENGTH OF HEAT SHRINK

TUBING APPROX 25mm LONG AND RUN

WIRES THROUGH IT AS SHOWN.

ONCE YOU HAVE MASTERED CRIMPING

CONTINUE CRIMPING A PIN ON ALL 4

WIRES AS SHOWN.

PINCH EACH CONNECTOR IN YOUR

FINGERS AND TUG ON IT TO MAKE

SURE IT DOESN’T COME OFF EASILY. IF

IT COMES OFF IT OBVIOSLY NEEDS TO

BE REDONE AND WASN’T FULLY

CRIMPED.

START TO FEED WIRES INTO FEMALE

HOUSING AS SHOWN.

USE A RAZOR BLADE TO MAKE SURE

THE TANGS ON EACH PIN ARE POINTED

OUT.

SOMETIMES THEY GET FLATTENED AND

WILL NOT LATCH INTO THE PLASTIC

HOUSING.

APPLY BLACK SILICONE AROUND THE

BASE OF THE CONNECTOR ON BOTH

SIDES AS SHOWN.

CONTINUE TO FULLY INSERT WIRES

INTO HOUSING.

NOTE THE TANGS ARE FULLY INSERTED

INTO THE SLOTS AND DO NOT PULL

BACK OUT

NOTE WITH THE SLOTS FACING YOU

THE BLUE WIRE IS ON TOP, THEN RED,

GREEN AND BLACK ON THE BOTTOM.

IT IS IMPORTANT THEY ARE INSERTED IN

THIS ORDER.

AFTER WORKING SILICONE INTO

CONNECTOR SPREAD IT A SHORT WAY

DOWN THE WIRES – IT SHOULD LOOK

LIKE THE PICTURE.

USE A TOOTHPICK TO WORK SILICONE

INTO EACH JACKET ON BOTH SIDES.

USE A HEAT GUN TO SHRINK THE

TUBING AS SHOWN.

THIS CONNECTOR IS NOW COMPLETE

SLIDE THE LENGTH OF HEAT SHRINK

TUBING OVER THE CONNECTOR AS

SHOWN.

SECTION 2

FEMALE 3 PIN JST CONNECTOR FOR LIMIT SWITCH END OF WIRING HARNESS

22

INSERT WIRES WITH FEMALE PINS INTO

THE 3 PIN FEMALE JST HOUSING AS

SHOWN.

NOTE WITH THE SLOTS FACING YOU

THE RED WIRE IS ON TOP, THEN GREEN

AND BLACK ON THE BOTTOM. IT IS

IMPORTANT THEY ARE INSERTED IN THIS

ORDER.

REMOVE THE BLUE STRAND FROM THE

RIBBON WIRE AS THIS CONNECTOR

ONLY REQUIRES 3 WIRES.

CRIMP FEMALE PINS TO THE ENDS OF

EACH OF THE WIRES STARTING WITH

THE RED WIRE AS SHOWN – REFER TO

INSTRUCTIONS IN SECTION 1 FOR

CRIMPING DETAILS.

APPLY SILICONE AND HEAT SHRINK

TUBING AS OUTLINED IN SECTION 1.

THIS CONNECTOR IS NOW COMPLETE.

SECTION 3

MALE 3 PIN JST CONNECTOR LIMIT

SWITCH PIGTAILS

25

NOTE THE LIMIT SWITCH FOR AXIS 6

USES A STRAIGH ARM LIMIT SWITCH

WITH THE J6 LIMIT SWITCH TIP

ATTACHED.

LIGHTLY SAND END OF LIMIT SWICH

ARM ON BOTH SIDES AND THEN USE

EPOXY TO SECURE J6 LIMIT SWITCH TIP

TO ARM OF SWITCH.

.STL PRINT FILE FOR THIS TIP CAN BE

FOUND ON PROJECT PAGE INCLUDED

WITH THE OTHER PRINT FILES FOR THE

COMPLETE PRINTED ROBOT.

CONNECT BLACK, RED AND GREY 22

AWG QUICK DISCONNECT WIRES TO

EACH LIMIT SWITCHES FOR ALL 6 AXIS.

NOTE: J1 THROUGH J5 WILL USE THE

ROLLER LIMIT SWICH SHOWN. J6 WILL

USE A STRAIGH ARM WITH TIP

EXTENSION SHOWN IN THE NEXT

STEP.

27

Cut quick disconnect wires to length for each switch as shown below

INSERT WIRES INTO MALE JST HOUSING

AS SHOWN – WITH CLIP FACING

FORWARD INSERT RED WIRE ON TOP,

GREY IN THE MIDDLE AND BLACK ON

THE BOTTOM.

CRIMP JST MALE PINS TO RED, GREY

AND BLACK WIRES IN THE EXACT SAME

PROCEEDURE OUTLINED IN SECTION 1

FOR ALL 6 LIMIT SWITCHES.

PLACE SILICONE AROUND WIRES AT

BASE OF JST HOUSING AND WORK

SILICONE INTO REAR OF CONNECTOR

IN THE SAME WAY SHOWN IN SECTION

1.

INSERT PINS UNTIL THEY ARE FULLY

SEATED AND CLICK INTO THE

HOUSING.

PLACE SHORT LENGTH OF HEAT

SHRINK TUBE OVER WIRES AND ONTO

JST CONNECTOR AS SHOWN.

WRAP WIRES WITH 4mm SPIRAL WRAP –

MAKE SURE SPIRAL WRAP EMBEDS INTO

SILICONE BEFORE IT CURES.

AFTER ALL 6 LIMIT SWITCH PIGTAILS ARE

COMPLETE USE PAINT PENS TO MARK

THE CONNECTORS AS SHOWN ON THE

NEXT PAGE

USE HEAT GUN TO SHRINK TUBING

AROUND CONNECTOR AND WIRES.

32

MARK CONNECTORS AS SHOWN

SECTION 4

MALE 4 PIN JST CONNECTOR ON

MOTOR PIGTAILS

33

34

CUT MOTOR WIRES TO THE FOLLOWING LENGTHS

SLIDE SHORT LENGTH OF HEAT SHRINK

TUBE OVER WIRES.

CRIP MALE JST PINS AS OUTLINED IN

SECTION 1TO EACH WIRE ON ALL 6

MOTORS.

INSERT WIRES INTO MALE JST HOUSING

AS SHOWN. – MAKE SURE THEY FULLY

CLICK INTO PLACE.

MAKE SURE WITH THE CLIP FACING YOU

THAT THE BLUE WIRE IS ON THE LEFT,

THEN THE RED, GREEN, AND BLACK ON

THE RIGHT.

NOTE: THE MOTORS FOR J5 AND J6

HAVE DIFFERENT WIRE COLORS, SEE

ELECTRICAL SCHEMATIC FOR CORRECT

COLOR ORDER.

WRAP 4mm SPIRAL WRAP AROUND

WIRES AND SLIDE UNDER HEAT SHRINK

WRAP AS ITS WRAPPED.

J5 motor J6 motor

FINSIH WRAPPING SPRIRAL WRAP INTIL

WRAP IS EMBEDDED INTO SILICONE..

APPLY BLACK SILICONE TO WIRES AND

CONNECTOR – WORK SILICONE INTO

BACK OF CONNECTOR WITH TOOTH

PICK.

USE HEAT GUN TO SHRINK TUBING AS

SHOWN.

SLIDE HEAT SHRINK TUBE OVER

CONNECTOR AS SHOWN.

APPLY BLACK SILICONE TO THE BASE OF EACH PIGTAIL.

40

MARK EACH CONNECTOR WITH PAINT PENS AS SHOWN

SECTION 5

WIRING HARNESS ASSEMBLY

41

42

CUT 6 LENTHS OF 4-STRAND

RIBBON WIRE TO THE

FOLLOWING LENTHS:

J1- WIRE = 40.6cm (16”) LONG

J2- WIRE = 71cm (28”) LONG


J4- WIRE =86.3cm (34”) LONG

J5- WIRE = 86.3cm (34”) LONG


CONNECT 4 PIN FEMALE JST

CONNECTOR TO ONE END OF EACH

WIRE AS OUTLINED IN SECTION 1.

Use paint pens to mark each end

of the motor wires as shown:

45

CUT 6 LENTHS OF

STRANDED RIBBON WIRE TO

THE FOLLOWING LENTHS –

STRIP OFF THE BLUE WIRE

FROM EACH SO THAT YOU

HAVE 3 STRAND WIRES (RED,

GREEN, BLACK):


J2- WIRE = 58.4cm (23”) LONG

J3- WIRE = 86.4cm (34”) LONG

J4- WIRE =86.4cm (34”) LONG



THES 6 WIRES WILL BE FOR THE

LIMIT SWITCHES.

STRIP 6mmTO 8mm FROM THE OTHER

END OF THE LIMIT SWITCH WIRES

INSTALL 3 PIN FEMALE JST CONNECTOR

AS OUTLINED IN SECTION 2 ON THE

END OF EACH OF THE 6 LIMIT SWITCH

WIRES.

USE RED PAINT PEN TO MARK THE J3

LIMIT SWITCH WIRE AT BOTH ENDS AS

SHOWN.

USE BLUE PAINT PEN TO MARK THE J2


SHOWN.

NOTE: AS BEFORE THE J1 WIRE DOES NOT

NEED TO BE MARKED.

USE WHITE PAINT PEN TO MARK THE J5


SHOWN.

NOTE: AS BEFORE THE J6 WIRE DOES NOT

NEED TO BE MARKED.

USE YELLOW PAINT PEN TO MARK THE

J4 LIMIT SWITCH WIRE AT BOTH ENDS

AS SHOWN.

PULL ALL MOTOR AND LIMIT SWITCH

WIRE ENDS THROUGH PG16 GLAND

NUT AS SHOWN

USE STEPPED BIT TO DRILL 7/8” HOLE IN

END OF PROJECT BOX.

PULL LIMIT SWITCH WIRES FAR

ENOUGH OUT OF BOX TO GIVE

YOURSELF SOME ROOM TO WORK. ON

THE STRIPPED END OF LIMIT SWITCH

WIRES – SEPARATE THE WIRE STRANDS

THEN TWIST ALL THE RED WIRES

TOGETHER AND THEN TWIST ALL THE

BLACK WIRES TOGETHER.

INSTALL WIRE LOOM AND GLAND NUT

INTO PROJECT BOX AS SHOWN.

CUT OFF MALE END OF RJ45

EXTENSION WIRE AND STRIP OFF

OUTER SHEETHING AS SHOWN.

SLIP 2.5cm (1”) LENGTH OF 6mm HEAT

SHRINK TUBING OVER RED AND BLACK

WIRE BUNDLES.

SLIP 2.5cm (1”) LENGTH OF 2mm HEAT

SHRINK TUBING OVER EACH OF THE

GREEN WIRES.

SOLDER BROWN WIRE FROM RJ45 TO

THE GROUP OF RED WIRES AS SHOWN.

THE FOLLOWING STEPS WILL CONNECT THE GREEN LIMIT SWITCH WIRES TO THE CORRECT RJ45 WIRES.

THE IMAGE TO THE LEFT SHOWS THE COLOR CODE FOR WHICH RJ45 WIRE GOES TO WHICH LIMIT SWITCH

J1 = WHITE / ORANGE STRIPE

J2 = ORANGE / WHITE STRIPE

J3 = WHITE / GREEN STRIPE

J4 = BLUE / WHITE STRIPE

J5 = WHITE / BLUE STRIPE

J6 = GREEN / WHITE STRIPE

COMMON NEGATIVE = WHITE / BROWN STRIPE.

COMMON POSITIVE = BROWN / WHITE STRIPE.

SOLDER WHITE / BROWN STRIPE WIRE

TO THE GROUP OF BLACK WIRES.

SLIDE HEAT SHRINK TUBE OVER SOLDER

JOINT AND USE HEAT GUN TO SHRINK

TUBE.

TRACE UNPAINTED GREEN WIRE FROM

SHORT J1 LIMIT SWITCH WIRE AND

SOLDER TO THE WHITE / ORANGE

STRIPE WIRE.

THEN SLIDE HEAT SHRINK TUBE OVER

SOLDER JOINT AND SHRINK WITH

HEAT GUN.

SLIDE HEAT SHRINK TUBE OVER SOLDER

JOINT AND USE HEAT GUN TO SHRINK

TUBE.

FIND THE J3 LIMIT SWITCH WIRE

WHICH WAS MARKED WITH RED PAINT

PEN AND SOLDER TO THE WHITE /

GREEN STRIPE WIRE.



HEAT GUN.


WHICH WAS MARKED WITH BLUE

PAINT PEN AND SOLDER TO THE

ORANGE / WHITE STRIPE WIRE.



HEAT GUN.


WHICH WAS MARKED WITH WHITE

PAINT PEN AND SOLDER TO THE WHITE

/ BLUE STRIPE WIRE.



HEAT GUN.


WHICH WAS MARKED WITH YELLOW

PAINT PEN AND SOLDER TO THE BLUE /

WHITE STRIPE WIRE.



HEAT GUN.

SLIDE THE LARGE 10mm HEAT SHRINK

TUBE OVER THE ENTIRE BUNDLE OF

JOINTS AND USE HEAT SHRINK GUN TO

SHRINK TUBING.

FIND THE REMAINING J6 LIMIT SWITCH

WIRE WHICH WAS NOT MARKED AND

SOLDER TO THE GREEN / WHITE STRIPE

WIRE.



HEAT GUN.

Use drill bit and rotary tool bit to create a

square hole at end opposite the 6 holes as

shown. Hole should be 7/8” x 3/4” to

accept the RJ45 panel mount plug.

USE STEPPED BIT TO DRILL (x6) 5/8”

diameter holes evenly spaced as shown.

Holes are 7/8” from edges and 1” apart.

Solder the J1 motor wires to the back side

of aviation plug as shown.

Looking at the back of the connector solder

the black wire to upper left , green wire

upper right, red wire to lower left and the

blue wire to lower right.

Install (x6) male side 4pin aviation plugs and

(x1) RJ45 panel mount jack as shown in

project box cover.

Install RJ45 plug into panel socket.

Solder the remaining motor wires to aviation

plugs as shown.

Work10mm wire wrap under gland nut and

into gland.

Carefully pull wire slack out and install cover

on project box.

Use digital multi meter to test continuity on

every pin of every motor wire and every

limit switch wire.

Tighten gland nut.

IF YOU WILL BE USING A PNEUMATIC GRIPPER LAY PNEUMATIC LINES ALONG WITH

WIRE BUNDLES. THE PNEUMATIC LINES CAN BE AS LONG AS YOU WANT BUT MAKE

SURE THE PNEUMATIC LINES EXTEND APPROX 8” PAST THE J6 CONNECTORS AT THE

VERY END OF THE HARNESS.

WRAP BUNDLE WITH 10mm SPIRAL WRAP AS SHOWN – WHEN YOU ARE 15.25cm (6”)

FROM END OF ENCLOSURE PULL THE J1 MOTOR AND LIMIT WIRES OUT OF THE

BUNDLE.

CONTINUE WRAPPING SPIRAL WRAP PAST THE SPOT WHERE THE J1 WIRES EXIT THE

WRAP – THEN ATTACH A MOUNTING CABLE TIE AS SHOWN.

CONTINUE WRAPING BUNDLE WITH SPIRAL WRAP – WHEN YOU ARE 40.5cm (16”) FROM

ATX CONNECTOR PULL THE J2 MOTOR AND LIMIT WIRES AS WELL AS THE J2 MOTOR

OUT OF THE WRAP AS SHOWN.

CONTINUE WRAPPING BUNDLE WITH SPIRAL WRAP – WHEN YOU GET JUST PAST 69cm

FROM ATX CONNECTOR BREAK THE J4 AND J5 MOTOR CONNECTORS AND J2 AND J4

LIMIT CONNECTORS OUT OF THE WRAP. THEN PLACE A MOUNTING CABLE TIE 68.5cm

FROM ATX CONNECTOR.

CONTINUE WRAPPING BUNDLE AND PLACE ANOTHER MOUNTING CABLE TIE 15.25cm

(6”) FROM PREVIOIUS CABLE TIE.

CONTINUE WRAPPING SPIRAL WRAP ALL THE WAY TO THE J6 CONNECTORS AS

SHOWN. INSTALL MOUNTING CABLE TIE AT END OF SPIRAL WRAP AS SHOWN.

GO BACK TO THE J2 & 3 MOTOR AND LIMIT WIRES THAT EXIT THE LOOM AND WRAP

THEM IN SPIRAL WRAP AND THEN WRAP THE JOINT WITH ELECTRICAL TAPE AS

SHOWN.

67

WIRING HARNESS IS NOW COMPLETE

SECTION 6

WIRING HARNESS INSTALLATION

68

SECURE THE HARNESS TO THE J2 ARM

USING M4 SCREWS THROUGH THE

CABLE TIE MOUNTS AS SHOWN.

SECURE HARNESS TO BASEPLATE USING

M4 SCREW ANDTHEN CONNECT THE J1

MOTOR AND LIMIT SWITCH

CONNECTORS.

CONNECT THE J2 & J3 MOTOR

CONNECTORS AND THE J2 LIMIT

SWITCH CONNECTOR AS SHOWN.

ROUTE THE J2 & J3 MOTOR AND LIMIT

SWITCH WIRES THROUGH THE CENTER

OF ROBOT AND THEN SECURE TO THE

J2 MOTOR SUPPORT PLATE USING A

STANDARD CABLE TIE THROUGH THE

SIDE HOLE AS SHOWN.

THE CABLE TIE SHOULD REMAIN LOOSE

AROUND THE WIRES – JUST TIGHT

ENOUGH SO THE CONNECTORS CANT

SLIP THROUGH THE TIE AND THE WIRES

CANT SWING INTO THE J2 LIMIT

SWITCH.

SECURE THE END OF THE HARNESS TO

THE J5 SUPPORT ARM AS SHOWN USING

A M4 SCREW AND THEN CONNECT THE

J5 & J6 CONNECTORS AS WELL AS THE

PNEUMATIC GRIPPER TUBES.

THIS CONCLUDES THE WIRING

HARNESS MANUAL – PLEASE VISIT

THE PROJECT PAGE AND REVIEW

THE VIDEO ON STARTUP AND

CALIBRATION.

CONNECT THE J4 & J5 MOTOR AND

LIMIT SWITCH CONNECTORS AS

SHOWN.

SECTION 7

MOTOR CABLES

72

Strip 10mm of outer sheathing off each end

of cable.

You will need to make 6 cables for the robot

and a 7th if you are building a travel track.

Cut each cable to whatever length you need

– in this example I have cut each cable to 6’

long.

Pre apply solder to each contact on

connector.

Strip 5mm sheathing off each wire and then

tin each wire with solder as shown.

Cables are “straight through” -

solder wires on each end of cable

mirror image to the other as

shown in the sketch and photo

shown.

Solder wires to each contact on connector –

see following steps for wire position.

Slide connector housing over connector and

install screw.

Wrap electrical tape around solder joints to

prevent any potential short on connector

housing.

Repeat this process for each cable needed.

Tighten screws on wire clamp.

model ar2 wiring harness

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